CONSTRUCTING A BUILDING TECHNICAL FIELD

The present invention relates to a pre-fabricated structural building panel for use in buildings. The present invention also relates to constructing a building using pre-fabricated building panels.

BACKGROUND

Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

Prior art building blocks and walls such as concerning tilt slab construction are well known. In most of these cases there are still considerable costs and expenses especially to third-world countries or where buildings need to be quickly erected following natural disasters and the like.

While there are various methods of construction addressing these prior art problems, most existing methods are based on conventional building processes using materials such as concrete moulded blocks for example BESSER ™ blocks and concrete reinforced products such as cement reinforced rice-husk building blocks and the like.

There is therefore a worldwide need for a comprehensive and competent building method and product which affords the comfort and security of conventional buildings in more developed countries for application in developing nations. In these situations and environment there is an overriding need for housing to be quickly built to solve problems such as in the case of natural disasters. The design of must also lend itself to be erected easily and with minimal skill and tooling and be able to fabricated onsite or offsite from a variety of materials.

SUMMARY OF THE INVENTION

In a first aspect, the invention provides a prefabricated structural building panel for use in buildings, the panel comprising: a pair of opposed sheets with a core therebetween, the core comprising a pre-cast composite material;one or more internal channels located in the core for receiving settable building material during use.

In an embodiment, a first set of internal channels extend along an orthogonal direction relative to an in use supporting surface for the building panel. Preferably, the internal channels extend along a generical direction of a longituidinal edge of the panel.

In an embodiment, the prefabricated structural building panel further comprises a fastening arrangement for fastening one or more of the building panels to each other during use. Preferably, the fastening arrangement comprises a tongue and groove fastening arrangement for fastening one or more building panels during use.

In an embodiment, the tongue and the groove may be provided along respective opposed sides of the building panel.

Preferably, the tongue extends outwardly from the core and the groove is defined by opposed internal walls of the opposed sheets. Furthermore, the tongue provided on a first building panel may be adapted for being receivably engaged in the groove of another adjacent building panel during use.

In an embodiment, the tongue may be adapted for engagement with a building member during use. In an embodiment, the core comprises one or more of the following materials: concrete, fly-ash, polystyrene, perlite, vermiculite or a combination thereof.

In an embodiment, at least some of the channels are adapted for receiving a substantially vertically oriented supporting or reinforcing member extending outwardly from a supporting surface for the building.

In an embodiment, the prefabricated structural building panel comprises another set of internal channels that extend in a transverse direction relative to the sheets. In some embodiments, the channels extend horizontally across the core of the building panel.

In an embodiment, the sheets comprise any one or more of the following materials: gyprock, magnesium oxide, fibre cement.

In one embodiment, an outwardly facing surface of the sheets may be adapted to be rendered by a rendering material.

In another embodiment, an outwardly facing surface of the sheets is pre- rendered.

In yet another embodiment, an outwardly facing surface of the sheets is adapted for receiving a cladding panel or an internal wall panel during use. In yet another embodiment, at least one of the opposed sheets comprises a cladding panel or an internal wall panel.

In some embodiments, the panel may be adapted for supporting a lintel or beam in a building during use. Preferably, another fastening arrangement may be provided for fastening the lintel or beam to the one or more building panels during use.

In an alternative embodiment, the building panel may comprise a load bearing member integrated into the building panel. In an embodiment, the building panel may be a load bearing building panel.

In an embodiment, the core comprises a third set of channels adapted for receiving reinforcement members and settable material thereby providing a bracing arrangement during use. Preferably, some of the channels may comprise one or more of transversely oriented channels extending diagonally across the building panel. Still more preferably, at least two transversely oriented channels may intersect each other at an intersecting position, the intersecting position being located in between the opposed sheets.

In some embodiments, two or more of the transversely oriented channels may be adapted for receiving reinforcement members for providing a bracing arrangement during use. A prefabricated structural building panel in accordance with any one of the preceding claims wherein the building panel comprises a load bearing member integrated into the building panel.

In another aspect, there is provided a modular building system comprising one or more of the prefabricated building panels in accordance with any one of the preceding claims.

In yet another aspect, the invention provides a method of constructing a building, the method comprising the steps of: providing a plurality of prefabricated building panels, each panel comprising: a pair of opposed sheets with a core therebetween, the core comprising a light-weight composite material; one or more internal channels located in the core; positioning said building panels on a supporting surface to thereby locate vertically oriented reinforcing members extending outwardly from the supporting surface into the channels; and introducing settable cementitious material into the channels.

In an embodiment, the method further comprises the step of fastening one or more of the building panels to each other, the fastening arrangement preferably comprising a tongue and groove fastening arrangement for fastening one or more building panels.

In a further embodiment, the comprises the step of fastening one or more load bearing members such as lintels or beams to said one or more building panels.

In an embodiment, the method further comprises the step of rendering an outwardly facing wall of the opposed sheets with a rendering material.

In an embodiment, the method further comprises the step of bracing the prefabricated building by introducing reinforcement members and/or settable material into two or more of the channels, said two or more channels being transversely oriented and positioned diagonally across the building panel.

In another aspect, there is provided a pre-rendered mould for a building block or wall panel including in combination: a pair of opposed externally rendered and spaced sheets, said sheets comprising a lightweight hollow composite mould or form-work for concrete to be placed there between;the mould including internal channels into which the pouring of wet concrete, which on curing, integrally and structurally supports the sheets to form an interstitial concrete cored pre-rendered building block or wall panel.

In yet another aspect, there is provided a method of constructing a building using the pre-rendered mould, said method including the steps of: laying a foundation on the ground; including in the foundation spaced vertical reinforcement rods (rebar); sliding onto the reinforced rods the pre-rendered mould; filling the space and channels between the sheets with wet concrete;allowing the concrete to cure to form an interstitial concrete externally pre-rendered building block or wall panel, likewise forming other blocks or wall panels, and joining them using specially adapted joining pieces including lintels and corner pieces to construct the building. BRIEF DESCRIPTION OF THE DRAWINGS

Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: Figure 1 shows an exploded perspective view of an embodiment of the invention.

Figure 2A-2C show plan, side and end views of the embodiment depicted in Figure 1 .

Figure 3 shows a cross-section of an embodimnent of the invention used in the construction of a building.

Figure 4 shows another embodiment of the invention with increased load bearing capacity according to the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Figure 1 shows an exploded perspective view of a building system 100 comprising a plurality of building panels in accordance with an embodiment of the present invention. Prefabricated building panels 10, 12, 14, 16, each comprise pairs of opposed externally rendered and spaced sheets 10a, 10b; 12a, 12b; 14a, 14b; 16a, 16b respectively.

Each of the panels 10, 12, 14, 16 also includes a respective core 10e, 12d, 14d, 16e that is spaced in between the respectived opposite sheets 10a, 10b; 12a, 12b; 14a, 14b; 16a, 16b respectively. The core 10e, 12d, 14d and 16e comprises a pre-cast lightweight composite material. In the preferred embodiment, the core is substantially composed from a light weight cemementitious admixture comprising flyash and polystyrene beads dispersed uniformly throughout the core of the respective panels 10, 12, 14 and 16. The present invention provides a significant advantages over the prior art. The configuration of the panels described herein allows the core of the panels to be cast or set in between the opposed sheets during the manufacturing process of the panels. As a result, the building panels 10, 12, 14 and 16 in accordance with embodiments of the present invention do not require the core portion to be cast or set at the building site and consequently the time taken for erecting building is substantially reduced.

The core of the building panels comprises internal channels 10c, 10d, 12c, 14c, 16c, 16d that extend in an orthogonal direction relative to the supporting slab on which the building panels are positioned. At least some of the channels 10c, 10d; 12c, 14c, 16c, 16d are adapted for receiving substantially vertically oriented supporting or reinforcing members in the form of rebars (not shown) extending outwardly from the supporting slab. Wet or settable cementitious material such as concrete may be poured into the channels receiving the rebars for fastening the building panel onto the supporting slab. The pouring of settable concrete through a substantial length of the channels assists with improving the overall load rating and strengthening of the building panels during use. Each of the building panels 10, 12, 14, 16 comprises a fastening arrangement for fastening or inter-locking adjacently positioned edges of the building panels 10, 12, 14, 16 with each other. Turning specifically to the fastening arrangement in between adjacent building panels 10 and 12, the core 10e of building panel 10 extends outwardly to form a tongue portion 10f that extends along a lateral side of panel 10. A groove portion 12g defined by opposed internal walls of the opposed sheets 12a and 12b is configured for receivably engaging the tongue portion 10f and thereby fastening adjacently located edges of building panels 10 and 12. Similarly configured tongue and groove type fastening arrangements are also provided for fastening adjacently located edges of panels 12, 14 and 16.

Advantageously, a tongue and groove arrangement is also provided for joining all the building panels 10, 12, 14 and 16 by way of using a lintel or beam 20. As illustrated, the upper edge for each of the building panels 10, 12, 14 and 16 is provided with an outwardly extending tongue portion that is configured for attachment to a corresponding groove located on the lintel or beam 20. Therefore, in some embodiments, the present invention provides a prefabricated building panel that is configured for engagement with structural support members such as lintels and beams.

Additionally, L-shaped structural connecting members such as corner piece 18 may also be provided for fastening the building panels that do not lie in the same place. Once again, a tongue and groove arrangement may be utilised for fastening the corner piece 18 with two or more building panels.

The outer surfaces of the sheets for each of the panels may be pre-rendered during fabrication of the panels. For example, the outer surfaces of the panels may be pre-rendered with a thin layer of plaster of a textured coating of cement reinforced with a plastic-covered wire mesh to accelerate the building process by not having to finish the wall on completion of the building.

In an alternative embodiment, an outer textured coating may be reinforced using a fibre glass mesh. Furthermore, in order to conform to dimensions of existing building, the building panels may be sized to produce a finished building block or wall panel of the thickness of a conventional brick wall.

Figures 2A-2C illustrate orthographic plan, top and side elevations of a prefabricated wall panel 15 in accordance with another embodiment. The panel 15 comprises a pair of opposed sheets 15a and 15b with a core 26 comprising a pre-cast composite material. The core 26 also comprises channels that extend along the core 26. The channels allow steel reinforcing bars 21 -24 and settable concrete material to be received into the channels. The spacing of the reinforcing bars 21 -24 may vary according to wind rating. The exterior of the panels 15a, 15b can be coated with lightweight concrete render, texture or clad with colour bond steel. Lintel 28 is attached to panel

15 by way of a tongue and groove arrangement as described in the previous sections. As illustrated, the upper edge of the building panel 15 is provided with an outwardly extending tongue portion that is configured for attachment to a corresponding groove located on the lintel or beam 28.

It will be understood that the described invention is in no way limited by the location of the tongue portion, for fastening the structural supporting members (such as lintels and beams), is not limited to the building panels. In alternative embodiments the tongue portion may be provided on the structural supporting members and a corresponding groove portion may be provided along the upper edge of the building panel. Figure 3 shows a cross-section of an embodiment of the invention in an use configuration. The wall panel 17 rests on footing 30 and is reinforced by steel bar 32 (according to requisite engineering specifications) tha is received into channels. Wall panel 17 is joined to other wall panels (not shown) by joining lintel 34 of a tongue and groove configuration. Lintel 34 has a groove 34a which fits concrete core tongue 17a of panel 17 and supports top plate 36 to which roof truss 38 is attached.

As shown in Figures 4A-4B illustrate another embodiment of the present invention that includes a bracing mechanism for providing increased load bearing capacity such as to comply with relevant building regulations. Transversely oriented channels 40a and 40c extend diagonally across the building panel and intersect at a substantially central intersecting location within the core of the panel 40. The core also includes a vertically oriented channel 40b that also intersects transverse channels 40a and 40c. Reinforcing bars or rods 42, 44 and 46 may be positioned into the channels 40a, 40b and 40c and settable cementitious material such as concrete may be poured into the channels for providing a bracing mechanism for the panel 40. ADVANTAGES

The major advantages conferred by embodiments of the invention include its:

• lightweight design

• ability to be manufactured both on and off site thereby eliminating downtime

• ability to be manufactured using a variety of materials, for example, lightweight concrete, polystyrene foam, pumice, etc.

• ability to be erected easily with minimal skill and tooling

• ability to be rendered with an outer covering of cement sheet, coloured steel or aluminium or any other suitable material

• ability to be reinforced to engineering specifications necessary to withstand cyclonic or other challenging weather conditions.

In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term "comprises" and its variations, such as "comprising" and "comprised of" is used throughout in an inclusive sense and not to the exclusion of any additional features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.

The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Throughout the specification and claims (if present), unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms. Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention. Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.